Exmark TT4819KAEC User manual

For Turf Tracer

Serial Nos. 510,000 & Higher

and

FMD524 & FMD604

Serial Nos. 510,000 & Higher

Part No. 103-9190

WARNING

POTENTIAL HAZARD

♦ This product is a piece of power equipment.

WHAT CAN HAPPEN

♦ Failure to follow safe operating practices can result in serious

operator injury or even death.

HOW TO AVOID THE HAZARD

♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condition.

♦ Stop engine and wait for all moving parts to stop. Remove spark

plug wire(s) or remove key before adjusting, servicing, or

performing maintenance.

♦ If mower deck becomes clogged, stop engine and wait for all

moving parts to stop. Remove spark plug wire(s) or remove key

before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts.

♦ Keep off mower unless seat platform is provided.

♦ Keep others off mower.

WARNING

POTENTIAL HAZARD

♦ Gasoline is harmful or fatal if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals.

WHAT CAN HAPPEN

♦ Failure to use caution may cause serious injury or illness.

HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors.

♦ Keep face away from nozzle and gas tank/container opening.

♦ Keep away from eyes and skin.

♦ Never siphon by mouth.

IMPORTANT

When the mower is used or operated on any California forest, brush or grass covered land, a working

spark arrester must be attached to the muffler. If not, the operator is violating state law, Section 4442

Public Resource Code. To acquire a spark arrester for your unit, see your Engine Service Dealer.

This spark ignition system complies with Canadian ICES-002

Ce système d’allumage par ètincelle de vèhicule est conforme à la norme NMB-002 du Canada

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S.

Environmental Protection Agency (EPA) and the California Emission Control Regulation

of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual

become damaged or illegible, replace immediately. Replacements may be ordered

through the engine manufacturer.

Exmark reserves the right to make changes or add improvements to its products at any time

without incurring any obligation to make such changes to products manufactured previously.

Exmark, or its distributors and dealers, accept no responsibility for variations which may be

evident in the actual specifications of its products and the statements and descriptions

contained in this publication.

- i -

EXMARK PARTS PLUS

®

PROGRAM

EFFECTIVE DATE: September 1, 1995

Program

If your Exmark dealer does not have the Exmark part in stock,

Exmark will get the parts to the dealer the next business day or

the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

the time of request by customer, the dealer contacts his

distributor by 1:00 p.m., local time, and requests Exmark

Parts Plus

®

shipment of six (6) line items or less.

2. Distributor ships part(s) to dealer or customer, as

requested by dealer, same day, overnight UPS

Distributor bills dealer for part and freight charges where

applicable.

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

®

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

®

order of six (6) line items or less.

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable.

5. The customer pays for the part

and freight if it is shipped under the Exmark Parts Plus

®

and if it arrives in

accordance to the program.

6. Who pays for the part

and freight if it fails to arrive overnight in accordance to the program?

A. Under any circumstance the customer does not pay.

B. If the part does not arrive overnight due to:

1. The dealer not submitting the Exmark Parts Plus

®

order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

®

order

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

Exmark pays for the part and freight.

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

pays for the part.

The following restrictions apply

-- The Exmark Parts Plus

®

Program is available only through participating Exmark

Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is only available

in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United

States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the

Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday

delivery shipments. To qualify, all Exmark Parts Plus

®

orders must be received by Exmark by 3:00 p.m., central time. Orders

must be six (6) line items or less. Exclusions from the Exmark Parts Plus

®

Program are: Any wholegood or accessory in its

entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or

hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight

restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or

Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered

for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

- ii -

CONGRATULATIONS on the purchase of your Exmark Mower. This product has been

carefully designed and manufactured to give you a maximum amount of dependability and

years of trouble-free operation.

OPERATOR'S MANUAL

This manual contains assembly, operating, maintenance, adjustment, and safety

instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS

ENTIRETY.

By following the operating, maintenance, and safety instructions, you will prolong the life

of your mower, maintain its maximum efficiency, and promote safe operation.

If additional information is needed, or should you require trained mechanic service,

contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distributors are kept informed of the latest methods

of servicing and are equipped to provide prompt and efficient service in the field or at their

service stations. They carry ample stock of service parts or can secure them promptly for you

from the factory.

All Exmark parts are thoroughly tested and inspected before leaving the factory,

however, attention is required on your part if you are to obtain the fullest measure of

satisfaction and performance.

- iii -

TABLE OF CONTENTS

1. SAFETY .............................................................................................PAGE

1.1 Safety Alert Symbol......................................................................................1

1.2 Training........................................................................................................1

1.3 Preparation................................................................................................1-3

1.4 Operation..................................................................................................4-6

1.5 Maintenance & Storage.............................................................................6-7

1.6 Riding Attachments...................................................................................... 7

1.7 Safety Signs........................................................................................ .....7-9

2. SPECIFICATIONS

2.1 Model Number............................................................................................10

2.2 Engine........................................................................................................ 10

2.3 Fuel System............................................................................................... 10

2.4 Electrical System........................................................................................ 10

2.5 Steering/Brake Control............................................................................... 10

2.6 Transmission.............................................................................................. 10

2.7 Wheel Drive System................................................................................... 10

2.8 Tires...........................................................................................................11

2.9 Deck........................................................................................................... 11

2.10 Dimensions ............................................................................................... 11

2.11 Torque Requirements................................................................................ 11

3. ASSEMBLY INSTRUCTIONS

3.1 to 3.12 Assembly...................................................................................12-15

4. OPERATION INSTRUCTIONS

4.1 Controls.................................................................................................15-17

4.2 Pre-Start..................................................................................................... 17

4.3 Operation Instructions...........................................................................17-19

4.4 Transporting............................................................................................... 20

5. MAINTENANCE & ADJUSTMENTS

5.1 Periodic Maintenance............................................................................20-29

5.2 Adjustments ..........................................................................................30-35

6. WASTE DISPOSAL

6.1 Motor Oil Disposal...................................................................................... 35

6.2 Battery Disposal......................................................................................... 35

7. TROUBLE SHOOTING

7.1 Mower Tracks Left or Right........................................................................ 35

7.2 Mower Cuts Unevenly ................................................................................ 36

7.3 Engine Will Not Start.............................................................................36-37

8. HYDRAULIC SCHEMATIC........................................................................... 38

9. WIRING DIAGRAM ....................................................................................... 39

10. WARRANTY................................................................................................. 40

- 1 -

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to

identify important safety messages which must be followed to avoid accidents. This

symbol means:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above information which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lettering / Red background. Indicates an imminently hazardous situation

which, if not avoided, WILL result in death or serious injury.

WARNING: Black lettering / Orange background. Indicates a potentially hazardous

situation which, if not avoided, COULD result in death or serious injury.

CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous

situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to

all who operate this unit.

1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the

proper use of the equipment. If the operator(s) or mechanic(s) can not read

English, it is the owner’s responsibility to explain this material to them.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow

children, teenagers, or people unfamiliar with these instructions to use the mower.

Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind

that the operator or user is responsible for accidents or hazards occurring to other

people or their property.

1.3 PREPARATION

1.3.1 Evaluate the terrain to determine what accessories and attachments are needed to

properly and safely perform the job. Only use accessories and attachments

approved by Exmark.

1.3.2 The use of personal protective equipment, such as (but not limited to) protection

for the eyes, ears, feet, and head is recommended.

CAUTION

POTENTIAL HAZARD

♦ This machine produces sound levels in excess of 85

dBA at the operator’s ear when in operation.

WHAT CAN HAPPEN

♦ Exposure to sound levels of 85 dBA or above for

extended periods of time can cause hearing loss.

HOW TO AVOID THE HAZARD

♦ Wear hearing protection when operating this machine.

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not

operate equipment when barefoot or when wearing open sandals.

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1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all

stones, sticks, wires, bones, and other foreign objects which may damage the

equipment or cause personal injury to the operator or bystanders.

WARNING

POTENTIAL HAZARD

♦ Engine exhaust contains carbon monoxide, which is

an odorless deadly poison.

WHAT CAN HAPPEN

♦ Carbon monoxide can kill you.

HOW TO AVOID THE HAZARD

♦ Do not run engine indoors or in a small confined area

where dangerous carbon monoxide fumes can collect.

DANGER

POTENTIAL HAZARD

♦ In certain conditions gasoline is extremely flammable

and highly explosive.

WHAT CAN HAPPEN

♦ A fire or explosion from gasoline can burn you, others,

and cause property damage.

HOW TO AVOID THE HAZARD

♦ DO NOT smoke while refueling, and stay away from

an open flame or where gasoline fumes may be ignited

by spark.

♦ Refuel only outdoors.

♦ Store gasoline in an approved container and keep it

out of the reach of children.

♦ Add fuel before starting the engine. Never remove the

cap of the fuel tank or add fuel when engine is running

or when the engine is hot.

♦ Never fill the fuel tank so that the gasoline level rises

above a level that is 1/2” below the bottom of the filler

neck to allow for gasoline expansion and prevent fuel

spillage.

♦ If fuel is spilled, DO NOT attempt to start the engine.

Move away from the area of the spill and avoid

creating any source of ignition until fuel vapors have

dissipated.

♦ Do not operate without entire exhaust system in place

and in proper working condition.

- 3 -

DANGER

POTENTIAL HAZARD

♦ In certain conditions gasoline is extremely flammable

and highly explosive.

WHAT CAN HAPPEN

♦ A static charge can ignite gasoline vapors. A fire or

explosion from gasoline can burn you, others, and

cause property damage.

HOW TO AVOID THE HAZARD

♦ Purchase and store gasoline only in an approved

container.

♦ Always place gasoline containers on the ground away

from your vehicle before filling.

♦ Do not fill gasoline containers inside a vehicle or on a

truck or trailer bed because interior carpets or plastic

truck bed liners may insulate the container and slow

the loss of any static charge.

♦ When practical, remove gas-powered equipment from

the truck or trailer and refuel the equipment with its

wheels on the ground.

♦ If this is not possible, then refuel such equipment on a

truck or trailer from a portable container, rather than

from a gasoline dispenser nozzle.

♦ If a gasoline dispenser nozzle must be used, keep the

nozzle in contact with the rim of the fuel tank or

container opening at all times until fueling is complete.

WARNING

POTENTIAL HAZARD

♦ Gasoline vapor can collect inside enclosed trailers and

may be ignited by electrical sparks or hot

engine/exhaust components.

WHAT CAN HAPPEN

♦ Explosion and fire may occur, resulting in property

damage, personal injury, and/or death.

HOW TO AVOID THE HAZARD

♦ Provide adequate ventilation of any enclosed trailer to

prevent build up of gasoline vapors, especially at floor

level.

♦ Refuel only outdoors, never inside an enclosed trailer.

♦ Be sure all fuel tanks and gasoline storage containers

have proper caps installed to prevent spillage and

minimize vapor escaping into the trailer.

♦ Do not place any equipment that is leaking gasoline in

an enclosed trailer.

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1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the

design and configuration of the equipment, these factors are also dependent upon

the awareness, concern, prudence, and proper training of the personnel involved in

the operation, transport, maintenance, and storage of the equipment. It is essential

that all Operator Safety Mechanisms be connected and in operating condition prior

to use for mowing.

WARNING

POTENTIAL HAZARD

♦ Operating engine parts, especially the muffler, become

extremely hot.

WHAT CAN HAPPEN

♦ Severe burns can occur on contact.

♦ Debris, such as leaves, grass, brush, etc. can catch fire.

HOW TO AVOID THE HAZARD

♦ Allow engine parts, especially the muffler, to cool before

touching.

♦ Remove accumulated debris from muffler and engine area.

♦ Install and maintain in working order a spark arrester before

using equipment on forest-covered, grass-covered, or

brush-covered unimproved land.

WARNING

POTENTIAL HAZARD

♦ Hands, feet, hair, clothing, or accessories can become

entangled in rotating parts.

WHAT CAN HAPPEN

♦ Contact with rotating parts can cause traumatic amputation

or severe lacerations.

HOW TO AVOID THE HAZARD

♦ Do not operate the machine without guards, shields, and

safety devices in place and working properly.

♦ Keep hands, feet, hair, jewelry, or clothing away from

rotating parts.

1.4.1 Give complete, undivided attention to the job at hand.

1.4.2 Mow only in daylight or in good artificial light, keeping away from holes and hidden

hazards. DO NOT operate the mower when children or others are in the area.

1.4.3 When feasible, avoid operating the equipment in wet grass.

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction

and/or tip-over could occur. The operator is responsible for safe operation on

slopes.

- 5 -

DANGER

POTENTIAL HAZARD

♦ Mowing on wet grass or steep slopes can cause sliding and

loss of control.

WHAT CAN HAPPEN

♦ Loss of control and/or loss of operator’s footing could result

in a fall with an arm or leg getting under the mower or

engine deck, which may result in serious injury or death.

HOW TO AVOID THE HAZARD

♦ Mow across slopes, never up and down.

♦ Do not mow slopes when grass is wet.

♦ Do not mow near drop-offs or near water.

♦ Do not mow slopes greater than 20 degrees.

♦ Reduce speed and use extreme caution on slopes.

♦ Avoid sudden turns or rapid speed changes.

• See inside the back cover to determine the approximate slope angle of the

area to be mowed.

• Progressively greater care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. If tires lose traction,

disengage the blades and proceed slowly off the slope.

• Be aware that loss of traction may occur going downhill. Weight transfer to

the front wheels may cause drive wheels to slip and cause loss of braking

and steering.

• Watch for ditches, holes, rocks, dips, and rises that change the operating

angle, as rough terrain could overturn the machine.

• Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing

area. Tall grass can hide obstacles.

• Use extreme care with grass catchers or attachments. These can change the

stability of the machine and cause loss of control.

1.4.5 Use EXTREME caution when backing up. LOOK BEHIND YOU!!

1.4.6 Stop the blades when crossing surfaces other than grass, if mower must be tilted

for transportation, and when transporting the mower to and from the area to be

mowed.

1.4.7 Never operate the mower with defective guards, shields, or covers. Always have

safety shields, guards, switches, and other devices in place and in proper working

condition.

1.4.8 Do Not change the engine governor settings or over speed the engine. Operating

an engine at excessive speed may increase the hazard of personal injury.

1.4.9 Place speed control lever in neutral, lock drive levers in neutral, disengage PTO,

and engage park brake before starting engine.

1.4.10 Start the engine carefully with feet well away from the blades.

1.4.11 Keep hands, feet, and clothing away from rotating parts while the mower is being

operated.

1.4.12 Stop the engine, wait for all moving parts to stop, and remove plug wire(s) or key:

• Before checking, cleaning or working on the mower.

• After striking a foreign object (inspect the mower for damage and make

repairs before restarting and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

- 6 -

1.4.13 Stop the engine and wait for all moving parts to stop:

• Before removing grass catcher.

• Before refueling.

• Before making height adjustments.

1.4.14 Before stopping the engine, place the throttle control midway between the “slow”

and “fast” positions. Allow the engine to run a minimum of 15 seconds, then stop

the engine.

1.4.15 The fuel system is provided with a shut-off valve. The fuel shut-off valve is used

to shut off the fuel:

• When the machine will not be used for a few days.

• During transport to and from the job.

• When parking inside a building.

1.4.16 This mower was designed for one operator only. Keep all others away from

mower during operation.

1.4.17 Do NOT mow with the discharge deflector raised, removed or altered unless

there is a grass collection system or mulch kit in place and working properly.

1.4.18 Be aware of the mower discharge and direct discharge away from others.

1.4.19 Do NOT operate the mower under the influence of alcohol or drugs.

1.4.20 Use extra care when approaching blind corners, shrubs, trees, or other objects

that may obscure vision.

1.4.21 If jump starting is required:

a) Connect the positive (+) power cable from the positive post on the booster

battery to the positive terminal post on the starter solenoid switch (this post

has the positive battery cable attached to it).

b) Connect the negative or ground cable (-) from the negative post on the

booster battery to the engine block as far away from the battery as

possible.

c) Disconnect battery cables in the reverse order after starting.

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine manufacture’s recommendations

precisely as stated in the engine manual.

1.5.2 Disconnect the battery from the negative battery post when the unit will be

allowed to sit for more than 30 days without use.

1.5.3 Allowing batteries to stand for an extended period of time without recharging

them will result in reduced performance and service life. To preserve optimum

battery performance and life, recharge batteries in storage when the open circuit

voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before

putting away for winter storage.

1.5.4 Keep engine and engine area free from accumulation of grass, leaves, excessive

grease or oil, and other debris which can accumulate in these areas. These

materials can become combustible and may result in a fire.

1.5.5 Store fuel in a container specifically designed for this purpose in a cool, dry place.

1.5.6 Keep the mower and fuel container in locked storage to prevent children from

playing or tampering with them.

- 7 -

1.5.7 Gasoline powered equipment or fuel containers should not be stored in a

basement or any enclosed area where open pilot lights or heat appliances are

present.

1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly maintaine

d

and operated correctly.

1.5.9 Check all bolts frequently to maintain proper tightness.

1.5.10 Keep all guards, shields, and all safety devices in place and in safe working

condition.

1.5.11 Frequently check for worn or deteriorating components that could create a hazard.

1.5.12 All replacement parts must be the same as or equivalent to the parts supplied as

original equipment.

WARNING

POTENTIAL HAZARD

♦ Hydraulic fluid escaping under pressure can penetrate

skin and cause injury.

WHAT CAN HAPPEN

♦ Fluid accidentally injected into the skin must be

surgically removed within a few hours by a doctor

familiar with this form of injury or gangrene may result.

HOW TO AVOID THE HAZARD

♦ Make sure all hydraulic fluid hoses and lines are in

good condition an all hydraulic connections and fittings

are tight before applying pressure to hydraulic system.

♦ Keep body and hands away from pinhole leaks or

nozzles that eject high pressure hydraulic fluid.

♦ Use cardboard or paper, not your hands, to find

hydraulic leaks.

♦ Safely relieve all pressure in the hydraulic system by

locking drive levers in neutral and shutting off the

engine before performing any work on the hydraulic

system.

1.6 RIDING ATTACHMENTS

Use only Exmark riding attachments. The use of other than Exmark riding attachments

may create a hazardous condition resulting in injury.

1.7 SAFETY SIGNS

1.7.1 Keep all safety signs legible. Remove all grease, dirt, and debris from safety

signs and instructional labels.

1.7.2 Safety signs must be replaced if they are missing or illegible.

1.7.3 When new components are installed, be sure that current safety signs are

affixed to the replaced components.

1.7.4 New safety signs may be obtained from your authorized Exmark equipment

dealer or distributor or from Exmark Mfg. Co. Inc.

1.7.5 Safety signs may be affixed by peeling off the backing to expose the adhesive

surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

1.7.6 Familiarize yourself with the following safety signs and instruction labels. They

are critical to the safe operation of your Exmark commercial mower.

- 8 -

PART NO. 103-1541

LOCATION: Console

PART NO. 1-403005

LOCATION: LH & RH Front Top

Surface of Mower Deck

PART NO. 1-303508

LOCATION: On Top RH Surface

of Mower Deck

PART NO. 1-303517

LOCATION: LH Side of Rear Surface of

Engine Deck

PART NO. 1-513746

LOCATION: Surface of Engine

Deck Next to Muffler

Type A Anti-Scalp Rollers Only – See Figure 9

PART NO. 1-323540

LOCATION: Front of Mower

Deck Top Surface

For FMD524 & FMD604 Units with SN 540,000 & Higher

PART NO. 103-7491

LOCATION: On Top Front RH Surface of Mower Deck

PART NO. 98-5954

LOCATION: Under LH, RH & Center Belt Shields

PART NO. 103-2242

LOCATION: LH Side of

Console

PART NO. 103-2243

LOCATION: RH Side of

Console

- 9 -

PART NO. 1-403143

LOCATION: RH Rear Surface of Engine Deck

PART NO. 1-513747

LOCATION: To

p

Rear of Batter

y

Cover

PART NO. 1-553049

LOCATION: On Top Front LH Surface of

Mower Deck

PART NO. 103-4935

LOCATION: Left Rear Top Corner

of Engine Deck

PART NO. 1-413214

LOCATION: Right Side of Hydro

Control Crank Arm

PART NO. 1-523552

LOCATION: On Top of

Hydraulic Tank

PART NO. 103-2239

LOCATION: Top of Mower Deck Beneath Center Shield

PART NO. 103-2432

LOCATION: Parking Brake

Lever

For FMD524 & FMD604 Units with SN 410,000 – 439,999

PART NO. 103-1077

LOCATION:

Front RH Side of Mower Deck

- 10 -

2. SPECIFICATIONS

2.1 MODEL NUMBER:

TT23KCC; TT23KAC; TT20KCC

2.2 ENGINE

2.2.1 Engine Specifications: See your Engine Owner's Manual.

2.2.2 3600 RPM (No Load).

2.3 FUEL SYSTEM

2.3.1 Capacity: 5.0 gal. (18.9 L.)

2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher. In countries

using the research method, it should be a 90 octane minimum.

2.3.3 Fuel Filter: Replaceable in-line

2.3.4 Fuel Shut-Off Valve: 1/4 turn

2.4 ELECTRICAL SYSTEM:

2.4.1 Charging System: Flywheel Alternator

2.4.2 Charging Capacity: 15 amp

2.4.3 Battery Type: BCI Group U1 235 amps at O° F

2.4.4 Battery Voltage: 12 Volt; Polarity, negative ground.

2.4.5 Fuses: blade type, 20 amp to charging circuit; 20 amp to electric clutch.

2.4.6 Safety Interlock System: Operator must have OPC (Operator Presence Control)

levers held in contact with handle grips, speed control lever in neutral, and PTO

disengaged to start engine. Release of OPC levers will cause the engine to stop

if speed control lever is not in neutral and/or PTO is engaged.

Park brake must be disengaged to move speed control out of neutral or engine

will kill.

2.5 STEERING CONTROL:

Fingertip drive control levers provide independent speed control, braking and neutral

to each drive wheel for moving forward or reverse, stopping, and power turning.

2.6 TRANSMISSION:

2.6.1 Two Hydro Gear BDP-10A variable displacement piston pumps independently

coupled to two high efficiency Parker wheel drive motors.

2.6.2 Hydraulic Oil: Use Mobil 1 15W-50 Synthetic Motor Oil.

2.6.3 Hydraulic Oil Capacity: 2.4 qt. (2.2 L.)

2.6.3 Hydraulic Filter is replaceable cartridge type.

P/N 1-513211: 10 microns, 18 psi bypass (Summer use above 32°

F (0° C))

P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32° F (0° C))

2.6.4 Speed Range: Forward 0 - 6.75 mph (10.9 km/h)

Reverse 0 - 2.25 mph (3.6 km/h)

2.6.5 Drive wheel release valves allow machine to be moved when the engine is not

running

2.7 WHEEL DRIVE SYSTEM:

Drive wheels are direct coupled to Parker wheel drive motors with 1.0" (25.4

mm) tapered shaft.

- 11 -

2.8 TIRES Drive Front Caster

Size ..........................18 x 8.50-8..........................11 x 4.0-5

Quantity............................2........................................ 2

Tread........................Turf Master........................... Smooth

Ply Rating.........................4........................................ 4

Pressure................14 psi (90 kPa)................. 16 psi (152 kPa)

2.9 MOWER DECK

2.9.1 Model Numbers: FMD604 and FMD524

2.9.2 Cutting Width: 60 in. (152.4 cm.)

52 in. (132.1 cm.)

2.9.3 Discharge: Right Side

2.9.4 Optional Mulch Kit and Bagger available.

2.9.5 Blade Size: 60" - (3 ea.) 20.50 in. (52.1 cm.)

52" - (3 ea.) 18.00 in. (45.7 cm.)

2.9.6 Type of Drive: Electric clutch mounted on engine shaft. Blades driven by two

belts with self tensioning idlers.

2.9.7 Adjustable anti-scalp rollers (6 ea.)

2.9.8 Cutting Height: Adjusts in 1/2” (1.3 cm) increments from 1 1/2” (3.8 cm) to 4

1/2” (11.5 cm).

2.9.9 Deck Mounting: Full floating deck is attached to out-front support frame,

removable for service.

2.10 DIMENSIONS

2.10.1 Overall Width:

w/52” Deck w/60” Deck

Discharge chute down

64.2” (163.1 cm) 72.2” (183.4 cm)

Discharge chute up

53.4” (135.6 cm) 61.4” (156.0)

2.10.2 Overall Length:

w/52” Deck w/60” Deck

83.4” (211.8 cm) 83.4” (211.8 cm)

2.10.3 Curb Weight*:

w/52” Deck w/60” Deck

720 lbs. (327 kg) 760 lbs. (345 kg)

∗ Weights will vary slightly depending on engine and handle option.

2.10.4 Overall Height: 45” (114.3 cm)

2.10.5 Tread Width (to outside of tires): 45.8” (116.3 cm)

2.11 TORQUE REQUIREMENTS

BOLT LOCATION TORQUE

Cutter Housing Spindle Nut (secured with threadlocker)...140-145 ft-lbs. (190-197 N-m)

Blade Mounting Bolt..................................................................55-60 ft-lbs. (75-81 N-m)

Mower Deck Support/Engine Deck Mount.................................30-35 ft-lbs. (41-47 N-m)

Anti-Scalp Roller (See Figure 9)

Type A – Whizlock Nut...............................................40-45 ft-lbs. (54-61 N-m)

Type B – Hex Capscrew.............................................50-55 ft-lbs. (68-75 N-m)

Type B – Nyloc Nut.....................................................30-35 ft-lbs. (41-47 N-m)

Engine Mounting Bolts ..............................................................15-20 ft-lbs. (20-27 N-m)

Wheel Lug Nuts ....................................................................90-95 ft-lbs. (122-129 N-m)

Clutch Retaining Bolt (secured with threadlocker).....................55-60 ft-lbs. (75-81 N-m)

- 12 -

3. ASSEMBLY INSTRUCTIONS

3.1 UNCRATE UNIT

3.1.1 Remove tractor and mower deck from crates.

3.2 SERVICE BATTERY:

The machine is shipped with a filled lead-acid battery.

3.2.1 Remove battery cover from machine.

DANGER

POTENTIAL HAZARD

♦ Charging the battery may produce explosive gasses

WHAT CAN HAPPEN

♦ Battery gasses can explode causing serious injury.

HOW TO AVOID THE HAZARD

♦ Keep sparks, flames, or cigarettes away from battery.

♦ Ventilate when charging or using battery in an

enclosed space.

♦ Make sure venting path of battery is always open once

battery is filled with acid.

3.2.2 Check the voltage of the battery with a digital voltmeter. Locate the voltage reading

of the battery in the table below and charge the battery for the recommended time

interval to bring the charge up to a full charge of 12.6 volts or greater.

IMPORTANT: Make sure the negative battery cables are disconnected and the

battery charger used for charging the battery has an output of 16 volts and 7

amps or less to avoid damaging the battery (see chart below for recommended

charger settings).

Voltage

Reading

Percent

Charge

Maximum

Charger Settings

Charging Interval

12.6 or greater 100% 16 volts/7 amps No Charging Required

12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour

12.0 – 12.2 25 – 50% 14.4 volts/4 amps 2 Hours

11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

CAUTION

POTENTIAL HAZARD

♦ If the ignition is in the “ON” position there is potential

for sparks and engagement of components.

WHAT CAN HAPPEN

♦ Sparks could cause an explosion or moving parts

could accidentally engage causing personal injury.

HOW TO AVOID THE HAZARD

♦ Be sure ignition switch is in the “OFF” position before

charging the battery.

3.2.3 Connect the negative battery cables.

WARNING: Battery posts, terminals, and related accessories contain lead compounds,

chemicals known to the State of California to cause cancer and re

p

roductive harm. Wash

- 13 -

NOTE: If the positive cable is also disconnected, connect the positive (red)

cable first, then the negative (black) cable. Slip insulator boot over the positive

terminal.

NOTE: If time does not permit charging the battery, or if charging equipment is

not available, connect the negative battery cables and run the vehicle

continuously for 20 to 30 minutes to sufficiently charge the battery.

3.4 DRIVE WHEELS

3.4.1 Check air pressure in drive tires; recommended pressure is 12-16 psi. Measure

circumference of each drive tire. Adjust tire pressure within 12-16 psi range to

try to make tire circumferences match as closely as possible.

3.5 MOWER DECK INSTALLATION

3.5.1 Release the wheel drive system by opening the drive wheel release valves. See

Section 4.1.11. Roll the tractor to the mower deck assembly and allow the tractor

assembly to tip backward until the rear of the engine deck contacts the ground.

3.5.2 Remove mower deck support frame from mower deck by removing the two

hairpins and spacers from the front deck support pins and by removing the two

hairpins and spacers from the rear deck support pins. See Figure 1.

3.5.3 Install mower deck support frame to tractor engine deck and secure using (8)

3/8-16 x 1 1/4” screws, (8) disc spring washers and (8) whizlock nuts from bolt

bag. See Figure 1.

NOTE: Place spring washer cone side against bolt head (cupped side away from head)

and install to outside of support frame as shown in Figure 1. Install with whizlock

nuts to the inside of engine deck. Tighten until spring washers are flat.

3.5.4 Position tractor with mower deck support frame in place, over the mower deck.

CAUTION

POTENTIAL HAZARD

♦ When mower deck is not installed or the two front

support rod hairpins are removed, the unbalanced

weight of the tractor or tractor with mounted mower

support frame may cause the front of the unit to rise

suddenly.

WHAT CAN HAPPEN

♦ If the unit rises suddenly, injury may occur.

HOW TO AVOID THE HAZARD

♦ Securely hold down the front end of the unit when the

mower deck is not installed.

Align and re-install the mower deck support pins into the support frame. Install

the two spacers and hairpins onto the front support pins and the two hairpins and

spacers onto the rear support pins. See Figure 1.

- 14 -

FIGURE 1

SUPPORT PIN LOCATION

3.5.5 Mower Deck Stationary Idler Installation:

Locate the two holes along the back center section of the deck and install the

stationary idler and related parts (from bolt bag) in the right hand hole. See

Figure 2. Be sure the coned end of the disc spring washer is against the head of

the bolt. Tighten hardware.

FIGURE 2

STATIONARY IDLER INSTALLATION

3.5.6 Install the deck drive belt around the clutch. Refer to belt routing decal. Be sure

belt is in the clutch drive sheave groove. Place the other end of the belt into the

V-groove of the stationary idler, move the spring loaded idler outward and route

the belt around the inside of the spring loaded idler. Position the belt into the V-

groove of the mower deck drive sheave. Carefully release the spring loaded

idler. Install the center belt shield.

3.5.7 Adjust cutting height of deck and anti-scalp rollers. See Adjustment Section 5.2.1.

3.6 POSITION DISCHARGE CHUTE:

Loosen two (2) 5/16” nyloc nuts attaching discharge chute. Lower the discharge

chute into position. Retighten nyloc nuts until chute is snug but can pivot freely.

3.7 SERVICE ENGINE: See Engine Operator's Manual.

3.8 SERVICE HYDRAULIC OIL

The machine is shipped with hydraulic oil in the reservoir. Run the machine for

approximately 15 minutes to allow any extra air to purge out of the hydraulic

system. Check hydraulic reservoir and if necessary fill the reservoir to the

appropriate level with Mobil 1 15W-50 synthetic motor oil. Replace hydraulic

reservoir cap and tighten until snug. Do not overtighten.

3/8-16 x 4 1/2

HEX CAPSCREW

- 15 -

NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with the

temperature of the oil. The “HOT” level shows the level of oil when it is at 225°F

(107°C). The “COLD” level shows the level of the oil when it is at 75°F (24°C). Fill

to the appropriate level depending upon the temperature of the oil. For example: If

the oil is about 150°F (65°C), fill to halfway between the “HOT” and “COLD” levels.

If the oil is at room temperature (about 75°F (24°C)), fill only to the “COLD” level.

3.9 GREASE UNIT:

NOTE: UNIT IS NOT GREASED AT THE FACTORY.

Refer to Maintenance Section 5.1.14 for grease zerk locations and grease amounts.

3.10 FAMILIARIZE YOURSELF WITH THE CONTROLS.

See Controls Section 4.1.

3.11 FOLLOW PRE-START INSTRUCTIONS.

See Pre-Start Section 4.2.

3.12 PERFORM NECESSARY ADJUSTMENTS.

See Maintenance and Adjustment Section 5.

4. OPERATION INSTRUCTIONS

4.1 Controls

4.1.1 Operator Presence Control (OPC) Levers

: Located on the upper handle

assembly directly above the handle grips. See Figure 3. When these levers

are depressed, the OPC system senses that the operator is in the normal

operator's position. When the levers are released, the OPC system senses

that the operator has moved from the normal operating position and will kill

the engine if either the speed control lever is not in the neutral position or the

PTO is engaged.

4.1.2 Drive Levers

: Located on each side of the upper handle assembly directly below

the handle grips. See Figure 3. These levers individually control the speed and

direction of each drive wheel. When the speed control lever is moved out of the

neutral position and the neutral lock latches are moved into the drive position, as

shown in Figure 3, and the drive levers are released, the drive wheels are

engaged in the forward direction.

Squeezing the left hand and/or right hand lever causes the left hand and/or right

hand drive wheel respectively to slow down, stop, or reverse, depending on how

far each drive lever is “squeezed”. Squeezing the drive levers beyond the neutral

position causes the drive wheels to engage in the reverse direction regardless of

the position of the neutral lock latches and the speed control lever.

4.1.3 Neutral Lock Latches

: These latches allow the operator to lock the drive levers in a

“neutral” position where the drive wheels are not engaged in either a forward or

reverse direction. See Figure 3.

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Exmark TT4819KAEC User manual

Exmark TT4819KAEC User manual

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